Self-sealing shingle



May 24, 1966 F. w. PRICE E AL 3,252,257

SELF-SEALING SHINGLE Filed NOV. 5, 1962 2 Sheets-Sheet 1 F i g 5 I INVENTORS Forest W Price Henry E Koopmann BY Wilfred A. Costa 5- r W Aflorneys May 24, 1966 F w, PRICE ET AL 3,252,257

SELF-SEALING SHINGLE Filed Nov. 5, 1962 2 Sheets-Sheet 2 JNVENTORS Forest W Price Henry E Koopmann BY Wilfred A. Costa Attorneys to effect a seal between shingles.

shingle the adhesive is expected to adhere to the back United States Patent 3,252,257 SELF-SEALIN G SHINGLE Forest W. Price, Berkeley, Henry F. Koopmann, Kensington, and Wilfred A. Costa, San Leandro, Calif.,'

This invention relates to flexible roofing and siding shingles of the conventional composition type and more particularly to improved shingles of this type having selfsealing characteristics.

Shingles of the asphalt composition type are universally used in the building industry for both roofing and siding due to their low cost, ease of application and acceptable durability. However, such shingles are subject to curling and lifting or even tearing when subjected to adverse wind conditions. In order to prevent wind damage to a composition shingle roof, diverse self-sealing shingles have appeared on the market. Generally these self-sealing shingles are of two types. Both types utilize an adhesive In the first type of of the shingle above it, whereas in the second type the adhesive is expected to adhere to the roofing granules of the shingle below it. The first type of shingle suffers from the defect that the backs of the shingles are customan'ly dusted with various powders or flaky materials such as mineral sand, dust or mica products. Such materials are dusted on the back of the shingles for the purpose of preventing adhesion or sticking while the roofing is packaged. Thus such materials destroy or inhibit the ability of the adhesive to stick to or bond with the shingle above it.

In the second type of self-sealing feature noted above, the adhesive is expected to stick to or bond with the roofing granules of the shingle below. In this case, the mechanism for forming the bond depends largely upon the adhesives ability to gradually flow, either by inherent softness or with the aid of the suns heat, into the irregular granular surface and thereby gradually establish a mechanical type of bond. However, if the adhesive is made soft enough to effect the bond without the aid of heat, it will generally tend to soften excessively and flow from under the shingle when heated by the sun. On the other hand if the adhesive is made relatively hard, the sealing will not be effected until such time as the suns heat is high enough to soften the adhesive whereby it can flow into the surface granules below. Most generally, however, the self-sealing shingles presently available, either of type one or of type two, require the suns heat to soften the adhesive and to condition it for bonding to the adjacent shingle.

The present invention overcomes the difficulties previously found in self-sealing shingles in that a seal is effected between the adjacent shingles immediately upon construction and without the necessity for external agents such as the suns heat to effectuate the bond. More specifically, such a bond is effected by providinga suitable adhesive on one shingle and a specially prepared receptive material area upon the underlying shingle. In addition, the shingles of the present invention are so constructed that they may be suitably stacked and packaged without the possibility of one shingle bonding to another before use.

It is therefore an object of the invention to provide a shingle which Will bond itself to an adjacent shingle upon contact.

It is another object of the invention to provide a selfsealing -shingle which will bond itself to adjacent shingles without the use of external agents such as heat.

It is yet another object of the invention to provide flexible composition shingles which when constructed into a roof in the conventional manner will have adhesive on one shingle in contact with the receptive material on an adjacent shingle.

It is yet another object of the invention to provide a self-sealing shingle having an adhesive thereon for bonding to a first subjacent shingle and an additional receptive material area for bonding to a superjacent second shingle.

Still another object of the invention is to provide selfsealing shingles having adhesives and receptive materials thereon but which can be packaged without the sticking or bonding of one shingle to another.

The invention will be more fully understood and further objects and advantages thereof will become apparent with reference to the detailed description which follows and to the accompanying drawings in which:

FIG. 1 is a plan view of the upper surface of a shingle embodying the present invention;

FIG. 2 is a view illustrating the underneath surface of a shingle of the invention;

FIG. 3 is a perspective view of the shingles of the invention in place upon a roof structure;

FIG. 4 is a cross-sectional view of the shingles of the invention in place upon a roof structure;

FIG. 5 is a perspective view of a stacked package of the shingles; and

FIG. 6 is a cross-sectional view of a stackedpackage arrangement of the shingles of the present-invention.

Referring now to the drawings, the invention is shown as comprising an otherwise conventional strip shingle 11. Such shingle 11 may be of conventional asphalt impregnated felt construction wherein felt is impregnated with an asphalt water-proofing compound. Alternately, shingle 11 may be constructed of any other conventional fiber-asphalt material commonly used in the roofing art. In any event, the strip shingle 11 comprises an elongated head lap portion 12 and an exposure tab portion 13. Exposure tab portion 13 is divided into a plurality of exposure tabs 14 by a series of spaced slots or cutouts 16 Slots 16 extend from the butt edge 17 of shingle 11 somewhat less than half way across the short dimension ,of the shingle to the head lap portion 12.

The entire upper surface 18 of shingle 11 is covered with a coating of mineral granules 19 with the exception, however, that a continuous strip 21 along the upper edge of head lap portion 12 is recessed below surface 18. One method of providing this recess is to apply ground sand at this area rather than mineral granules. Thus the surface of the ground sand covered strip 21 is somewhat lower than the upper surface of the rest of the shingle 11 which is covered With mineral granules 19. This thinner portion of shingle 11 serves a very useful purpose when the shingles are stacked as will be shown hereafter.

Additionally a thread 22 of receptive material is adhered to the upper surface 18 of shingle 11. Thread 22 comprises a series of spots, dots or a continuous line of receptive material extending longitudinally along the longer axis of shingle 11 at a point approximately midway between the butt and head edges thereof. The individual spots of thread 22 form a very thin coating over the mineral granules 19 of shingle 11. In addition the composition of the receptive material is extremely important to the operation and self-sealing features of the invention. The composition of the receptive material will be completely discussed hereinafter.

The reverse of underneath surface 23 of shingle 11 is lightly covered with a coating of mica flakes, talc or other similar material.

Additionally, as illustrated in FIGS. 2 and 5 of the drawings, the underneath surface 23 of shingle 11 has a lane of adhesive strips 24 adhered thereto; which lane of adhesive strips run longitudinally along the tab portions 14 of shingle 11 and are positioned a short distance inward of the butt end 17 thereof. These adhesive strips 24 are coated relatively thickly upon surface 23. The composition of the adhesive used to form strips 24 must be compatible with the composition of receptive spots 22 so that the self-sealing of the shingles is effected. This composition will be more fully described hereinafter.

As shown in FIG. 5 of the drawings, the bottom surface 23 of the shingle is also coated with two thin continuous stripes of adhesive 26 of a composition identical with the composition of adhesive strips 24. Adhesive stripes 26 are in turn covered with a continuous band of release paper 27. Release paper 27 is coated on its exposed side with a release agent such as a silicone. However, it is not so coated on the side in contact with adhesive stripes 26 whereby the paper will adhere firmly to said adhesive stripes but will release easily from any surface with which the exposed side comes into contact.

It should be further noted that adhesive stripes 26 and contact release paper 27 are placed in an area on shingle 11 corresponding to the ground sand covered area 21 on the face of shingle 11..

The application of the shingles of the invention to a roof structure is illustrated in FIGS. 3 and 4 of the drawings. Thus it can be seen that the shingles are applied in the conventional manner as with most other flexible composition shingles presently available on the market. Each succeeding course of shingles is nailed down to the roof so that the butt edges 17 of the exposure tabs 14 end at or slightly overlap the closed end of cutouts 16. When the shingles are laid in such a manner, it will be noted that the adhesive strips 24 are brought into contact directly with receptive thread spots 22. Due to the I It has been established that in order to form an effective wind resistant bond between the adhesive strips 24 on the underneath surface of the upper shingle and the receptive spots on the upper surface of the subjacent shingle, the adhesive composition and the receptive material composition must be carefully selected so as to be compatible. In this respect, the bond depends upon the receptive surface having as its sticking mechanism an initial adhesion established through the particular at-' traction between the adhesive and the receptive material. The receptive material is formulated or selected so that the adhesive adheres without dependence upon the adhesives ability to flow or to establish a mechanical locking action with the surface granules as hereinbefore described. Those materials that have been found to be most suitable for the receptive material are those that most readily wet asphalt, or conversely those which asphalt most readily wets. Thus, it has been established that the necessary wetting property is generally found in those materials which are highly soluble in bitumen. However, it should not be taken that solubility of the receptive material in bitumen is mandatory. Wetting action appears to be a better criterion of the compatibility of adhesive and receptive material.

Retaining the criteria as noted above in mind, it has been found that bituminous adhesive 24 may most suitably be composed of commercially available asphalt or a blend of two or more commercially available asphalts having generally the following properties:

Softening point, ball and ring130240 F. Penetration 77 F., 100 grams, 5 seconds, of 1-200.

Preferably, the asphalt or asphalt blend for use as adhesive 24 should have a softening point of 155-185 F.

. polymer of about 42 Mooney viscosity) available from E. I. du Pont de Nemours & Company, Inc.; Dow latex 2582 (vinyltoluene/butadiene copolymer of .981 specfic gravity at 25 C. and 25.0 Brookfield viscosity) available from Dow Chemical Company; Naugatex 2105 (70/30 butadiene-styrene copolymer of 140 Mooney and .20 micron particle size) available from Naugatuck Chemical Division of United States Rubber Company; powdered rubbers such as Neoprene PB commercially available from Du Pont and Hycar 1432 (Medium high acrylonitrile copolymer of .98 specific gravity and average Mooney) available from the B. F. Goodrich Chemical Company. While rubber latices or powdered rubber may be added up to ten percent of the total adhesive mixture, it is preferable to add the rubber in a range of from 2-5 percent.

The following examples will illustrate specific compositions which may be used as adhesive strips 24 on the flexible shingles of the invention:

Example 1 Percent Roofing coating grade asphalt,

220 F. softening point 40 Roofing saturant grade asphalt,

F. softening point 60 A typical blend softening point of the above composition is F., while the typical penetration is 35.

Example 2 Percent Roofing coating grade asphalt,

220 F. softening point 37 Roofing saturant grade asphalt,

120 F. softening point 57 Butyl latex MD 600-55, solids 6 (Butyl latex MD 600-55) a chemically stable emulsion of butyl rubber in Water; .96 specific gravity at 70 F. and 54-55 total solids) is commercially available from Enjay Chemical Company).

A typical blend softening point of the above composition is 180 F., while a typical penetration is 34.

Example 3 Percent Roofing coating grade asphalt,

220 F. softening point 29 Roofing saturant grade asphalt,

120 F., softening point 68 Neoprene PB 3 A typical blend softening point of the above composition is 150 F., while a typical penetration is 23.

The adhesive compositions as presented in the above examples should not be taken to be the only adhesives suitable for use on the shingles of the invention, but are merely illustrative of compositions which have been found to be suitable.

In order that a suitable bond will be established between succeeding courses of shingles when a roof is constructed, the composition of the receptive material as noted above must be carefully selected. Specifically it has been found that the receptive material is most suitably composed of a resin or a resin blend with or without a filler material added. This resin or resin blend receptive material should have the following general physical properties:

Softening Point, F. 90-160 Penetration 1-100 The preferred receptive material should have a softening point in the range of l20140 F. and a penetration in the range of -45.

Raw materials for use in preparing receptive material formulations may be selected from one of the following listed materials, although such formulation is not necessarily restricted to the material enumerated below:

Chemprene 50, available from Chemfax Incorporated Chemprene 50 is an alkyl substituted vinylcyclohexene polymer with a molecular weight of 850, a softening point ASTM B and R of 50 F.; a specific gravity of 1.1; an acid number of 0; a saponification number of 0; and a bromine number of 106.

Croturez A available from Crosby Chemicals Inc. Croturez A is a pure polymerized terpene resin polymerized with itself. It has a softening point ASTM B and R of 185 F.; a specific gravity of 0.981; and an acid number of 1.0.

Ester gum.

Neoprene PB available from the Du Pont Chemical CompanyNeoprene PB is a powdered composition of Neoprene rubber.

Duprex 22 available from the Shell Oil Company-Dutrex 22 is a petroleum resin predominantly of aromatic structure having a dark amber color.

SolventAromatic petroleum solvents are most suitable, i.e., Standard Oil Companys Socal No. 2 which has the following properties:

Distillation range in F. Initial 278 50% 292 95% -1 322 End point 336 Neoprene LD 260 emulsion, available from E. I. du Pont de Nemours and Company, Inc.Neoprene LB 260 emulsion is Neoprene rubber in a liquid vehicle.

Piccolyte S-l available from Pennsylvania Industrial Chemical Corporation. Piccolyte S-llS is a terpene resin having the following properties:

Softening point, F. 220 Density 0.980 Refractive index (at C.) 1.535 Color Gardner scale 1-3 Flash point COC F. 450 Molecular weight, approx 1,200 Acid number, approx. 0 Saponification number, approx. 0

It has been found that the above noted raw materials may be formulated into a suitable receptive material for use on the shingle of the invention. Examples of typical receptive material formulations follow. However, the following examples should be taken as being merely illustrative and not limiting as to the receptive material composition:

6 Example 4 Neoprene LD 260 emulsion 16 Emulsion (40% Chemprene 50,

% Ester gum) 1 84 ]3 mulsionthis emulsion may be produced as follows: Blend 204 pounds of ester gum and 136 pounds of Chemprene 50 at 210 F. Then add 40 pounds of oleic acid and mix well. Then add 18.5 pounds of morpholine and slowly add 200 pounds of water which has been heated to 180 F. while mixing the entire formulation, This produces an emulsion for use in the receptive material of Example 4 at about 50% solids.

will not come into contact prior to the construction of a roof when the bonding of one course of shingles to another is desired. However, due to the unique construction of the shingles and the careful placing of the adhesive strips 24 and receptive material threads 22, the shingles of the invention may be packaged into conventional packs without fear of prematurebonding or without destroying the adhesive and receptive surfaces.

Thus, as is illustrated in FIGS. 5 and 6 of the drawings, shingles 11 are stacked into conventional bundles; however, with the restrictions that successive shingles are stacked upper surface to upper surface and underneath surface to underneath surface while each successive shingle is rotated 180 with respect to its neighbor shingle. Thus, as will be noted from the illustrations, adhesive strips 24 of one shingle will bear against release paper 27 on the next succeeding shingle. Similarly the adhesive strips 24 on the succeeding shingle will bear against the release paper strip 27 of the preceding shingle. In this manner adhesive strips 24 are maintained free from contamination during storage and handling while the silicone surface on release paper 27 permits the shingle to be removed from the bundle without adhesive sticking.

In addition it should be noted that while in the bundle receptive material threads 22 never come into contact with adhesive strips 24 whereby there is no danger of the adhesive bonding to the receptive material prior to roof construction.

It should be further noted that ground sand covered strips 21 on the shingles reduce the shingle thickness to such an extent that when the shingles are stacked and packaged as shown, the thickness due to adhesive strips 24, stripes 26 and release paper 27 is insufficient to cause excess thickness at the bundle edges. Strip 21 serves as a bundle pressure relieving recess. Thus, the shingles may be packaged flat and are not subjected to concave warping across their short dimension.

A bundle of a suitable number of shingles is secured by conventional means, i.e., by wrapping with heavy paper or cardboard, for suitable storage and/ or transportation.

Although the self-sealing shingles of the invention have i been described in full detail, it should be understood that these details are merely illustrative and that various changes and modifications may suggest themselves to those persons skilled in the art. However, all such changes and modifications are intended to be coveredherein as falling material having a softening point between 120 and 140 F. and the ability to wet said bituminous adhesive, said adhesive and receptive mate-rial being so positioned that the adhesive of one shingle is in register with the receptive claim 1, wherein a filler material is incorporated in said resinous receptive material.

3. Flexible strip shingles, as claimed in claim 2, wherein said filler material is diatomaceous earth.

4. Self-sealing strip shingles, as in claim 1, wherein said adhesive consists of a mixture of about 40 percent roofing coating grade asphalt having a softening point of about 220 F. and 60 percent of roofing saturant grade asphalt having a softening point of about 120 F.

5. Self-sealing strip shingles, as claimed in claim 1, wherein said adhesive consists of about 29 percent roofing coating grade asphalt, having a softening point of 220 F., of about 68 percent roofing saturant grade asphalt having a softening point of 120 F., and of about 3 percent powdered neoprene rubber.

6. self sealing strip shingles, as claimed in claim 1, wherein said receptive material consists of about 40 percent of an .alkyl substituted vinylcyclohexene polymer having a molecular weight of about 850 and a specific gravity of about 1.1, about 50 percent of a ester gum, and about 10 percent of diatomaceous earth.

-7. Self-sealing strip shingles, as claimed in claim 1, wherein said receptive material consists of about 80 percent of a terpene resin, having a softening point of about 220 F., a molecular weight of approximately 1,200, and a density of about 0.980, and of about 20 percent dioctyl phthalate.

8. Self-sealing strip shingles, as claimed in claim 1, wherein said receptive material consists of about 3 percent powdered neoprene rubber, of about 40 percent petroleum resin, of about 37 percent of an alkyl substituted vinylcyclohexene polymer having a molecular weight of about 850 and a specific gravity of about 1.1, of about 5 percent ester gum, and of about 15 percent of an aromatic petroleum solvent.

9. Self-sealing strip shingles as in claim 1, wherein said bituminous adhesive consists of a mixture of about 37 percent roofing coating grade asphalt having a softening point of about 220 F., about 57 percent of roofing saturant grade asphalt having a softening point of about 120 F., and the remainder being a butyl latex rubber polymer.

10. A self-sealing flexible strip shingle comprising a shingle sheet having an upper surface and an underneath surface, said sheet further comprising a'head lap portion and an exposure tab portion, a lane of bituminous adhesive strips adhered to the underneath surface of said exposure tab portion and running longitudinally along said strip shingle, said adhesive having a softening point between 155 and 185 F., and a thread of resinous receptive material spots adhered to the upper surface of said sheet shingle, said receptive spots running longitudinally along said shingle strip thereby dividing said strip shingle into the head lap portion and exposure tab portion, said receptive material having a softening point between 8 120 and 140 F., and the ability to wet the adhesive, whereby contact between adhesive strips and receptive spots of successively laid shingles provides immediate bonding therebetween.

11. A self-sealing asphaltic composition strip shingle having an upper surface and an underneath surface, said shingle divided into a head lap portion and an exposure tab portion, said exposure tab portion being divided into a plurality of shingle-like tabs by a number of cutouts extending from the butt edge of said exposure tab portion to about the mid-portion of said strip shingle, a narrow strip-like area extending longitudinally along the edge of said upper surface remote from the butt edge of said exposure tab portion, said strip-like area being covered with a finely ground mineral material, the remainder of said upper surface being covered with a coating of roofing mineral granules, a lane of bituminous adhesive strips coated on the underneath surface of said exposure tab portion, said adhesive strips running longitudinally along said shingle-like tabs at a position inward from said butt edge said adhesive having a softening point between 155 and 185 F., a thread of resinous receptive material spots running longitudinally along the mid portion of said strip shingle, said receptive material having a softening point between and F. and the ability to wet said adhesive whereby contact between the adhesive strips and receptive spots of successively laid shingles provide immediate bonding therebetween, two adjacent lines of adhesive coated on the underneath surface of said strip shingle running longitudinally therealong and underlying the aforesaid strip-like area covered with a finely ground mineral coating, and a strip of release paper adhered to said adjacent lines of adhesive material.

References Cited by the Examiner ,UNITED STATES PATENTS 1,769,628 7/ 1930 Fischer 52-420 2,210,209 8/ 1940 Kirschbraun 52-420 2,300,488 11/ 1942 Cuno 52-420 2,667,131 1/1954 Clarvoe et al. 52-420 2,822,085 2/1958 Bettoli et al. 206-60 2,863,405 12/ 1958 Leibrook et a l. 52-420 2,885,073 5/1959 Bettoli et al. 206-60 2,935,416 5/1960 Dunbar et -al. 52-420 3,003,288 10/1961 Leibrook et a1. 52-420 3,032,928 5/1962 Jackson 117-168 3,042,193 7/ 1962 Wendt 52-420 3,080,683 3/1963 Sallie 52-173 3,082,557 3/1963 Fasold 52-543 3,138,251 6/ 1964 Ol-szyk 206-60 3,138,897 6/1964 McOorkle 52-420 OTHER REFERENCES Asphalt, and Allied Substances, 5th edition, by Abraham, 1945, pages 709 and 741, published by D. Van Nostrand.

FRANK L. ABBOTT, Primary Examiner.

EARL J. DRUMMOND, HENRY C. SUTHERLAND,

JACOB L. NACKENOFF, Examiners.

J. M. CASKIE, M. O. WARNECKE, J. E. MURTAGH,

Assistant Examiners. 

1. SELF SEALING FLEXIBLE STRIP SHINGLES WITH UPPER AND UNDERNEATH SURFACES HAVING A BITUMINOUS ADHESIVE ON AT LEAST A PORTION OF ONE SURFACE THEREOF, SAID BITUMINOUS ADHESIVE HAVING A SOFTENING POINT BETWEEN 155* AND 185* F., AND A RESINOUS RECEPTIVE MATERIAL FOR SAID ADHESIVE ON AT LEAST A PORTION OF OTHER SURFACE THEREOF, SAID RECEPTIVE MATERIAL HAVING A SOFTENING POINT BETWEEN 120* AND 140* F. AND THE ABILITY TO WET SAID BITUMINOUS ADHESIVE, SAID ADHESIVE AND RECEPTIVE MATERIAL BEING SO POSITIONED THAT THE ADHESIVE OF ONE SHINGLE IS IN REGISTER WITH THE RECEPTIVE MATERIAL ON ANOTHER SHINGLE WHEN SAID SHINGLES ARE SUCCESSIVELY LAID IN A ROOFING CONFIGURATION WHEREBY A BOND IS IMMEDIATELY ESTABLISHED BETWEEN SUCCESSIVE COURSES OF SHINGLES WHEN A ROOF IS CONSTRUCTED. 